①Dryer water reformation. The common problem is that the dryer configuration is low, generally two-column 24 drying cylinders, because the processing fabrics are mostly pure cotton thick fabrics, so the dryer consumes about 500kg / hour of steam. Due to the poor quality of the domestic steam trap, the leakage Large, generally 6% to 7%, therefore, with the removal of condensate, a large amount of steam is discharged, causing serious waste. In view of this, we removed the trap of the dryer's return water line and changed it to cut-off For the valve, install a one-way check valve behind it, and then directly introduce the outlet pipe into the flat washing tank before drying. In this way, the condensate and leaked steam are fully utilized, and the drying effect is improved.
②After deboiling and bleaching, clean water is reused. In the process configuration of the equipment, the deboiling and bleaching is generally carried out in three stages. As the process is further back, the fabric is cleaner, and the hot water discharged is also cleaner. The process requires that the amount of water used for washing in the latter stage is 3 tons / hour A large amount of hot water is discharged into the ditch in vain, which is a great waste. For this reason, we have self-made water storage tanks and automatic filtering devices to filter the hot water in the rear section, and use a micro pressure sensor to control the frequency conversion of the hot water pump to the cooking Segment second use.
③Waste heat recovery. When the clean water in the latter stage is introduced into the smelting stage for secondary use, the smelting stage can basically meet the production needs without adding any more water. These heats are finally eliminated after countercurrent water washing in the smelting stage. It still contains a lot of heat energy. For this reason, we specially purchased heat energy recovery equipment, replaced the hot water discharged from the cooking section with cold water heat energy, reheated 20 degrees of cold water to 60 ~ 70 degrees and then used it for the equipment. Recycling.
Pure acrylic low-twist rotor yarn is used for knitting velvet. The finished fabric has a good velvet effect, uniform and soft, bright color, and the fabric is neat and feels good. Therefore, product supply is in short supply. Our factory has developed 98 tex pure acrylic low-twist rotor yarn (twist is 270 twists / m) according to customer requirements. Now we will introduce spinning process parameters and corresponding technical measures.
a. Selection of raw materials
In order to make the fabric suede effect is good and has a stiffness, therefore, the organic combination of thick and thin fibers, long and short fibers must be considered in the selection of raw materials. Our factory selected 30% 1.67 dtex × 38 mm cotton acrylic staple fiber, 30% 3.33 dtex × 51 mm medium-length acrylic fiber and 3.33 dtex acrylic filament by special cutting to form 38 mm The acrylic staple fiber is specially cut in consideration of the suitable fiber length of the cotton rotor spinning machine.
b. Raw material pretreatment
Since the opening degree of acrylic fiber is not good enough, there are many yarns and bundles, the carding is difficult, the friction factor with the equipment is large, and static electricity is easily generated. The pre-opening equipment can use wool spinning type B262 and wool machine. The oil agent can use specially configured acrylic spinning auxiliary. It is required to have good antistatic effect, softness and smoothness to reduce the generation of static electricity and increase Spinnability. Refueling amount as raw material O. 2% -0. 3%, the amount of water added is 8% -12% of the raw material, and it can be appropriately increased or decreased by 2% to 4% according to the season and weather changes. Spread the loosened raw materials layer by layer, spray them evenly with a high-pressure nozzle, and then cover them with plastic film, and let them sit for 10 hours after use.
Economic benefit evaluation of energy saving and emission reduction effects
In the process of reforming the return water of the dryer, the leakage problem of the steam trap was completely overcome, and all the condensate was used, calculated according to the steam consumption of 500kg / hour: the daily steam saving is: 500 × 6% × 20 = 600kg, so The annual steam saving is: 600 × 300 = 180,000 kg, the steam price is 125 yuan / ton, and the annual economic benefit is 22,500 yuan.
In the reuse of clean water, it can save about 3 tons of hot water at 90 degrees per hour. It can be seen that the annual water saving of a single machine is: 3 × 20 × 300 = 18000 tons, which is about 76,000 yuan. Of course, the heat contained in the hot water is also very considerable. 18,000 tons of hot water is heated from 20 degrees to 90 degrees. The heat required is equivalent to about 2,000 tons of steam. Based on 125 yuan / ton of steam, it is equivalent to RMB 250,000. Comprehensive water and heat can be seen as a reuse of clean water, the annual benefit of a single machine will reach 326,000 yuan, very impressive.
In the waste heat recovery stage, the waste hot water (3 tons / hour) in the cooking section is replaced with cold water through a plate heat exchanger, and the waste hot water can be discharged at a temperature of 90 degrees to 20 degrees. Calculated for 300 days / year, the heat energy to be replaced in this way is 2,000 tons. Based on 125 yuan / ton of steam, the annual thermal energy savings of a single machine is equivalent to RMB 250,000.
